LIDAR Sensor Assembly Including Joint Coupling Features

ABSTRACT

A light detection and ranging (LIDAR) sensor assembly can comprise an optics assembly that includes a LIDAR sensor and a set of dovetail joint inserts. The LIDAR sensor assembly can further include a frame comprising a set of dovetail joint septums coupled to the set of dovetail joint inserts of the optics assembly.

BACKGROUND

Light detection and ranging (LIDAR) sensors can experience relativelyhigh forces due to fast spinning components and movement of a vehicleupon which the LIDAR sensor is mounted. The optics assembly of a LIDARsensor is typically held in place using clips and screws that connectwith holes or slots on an optical frame.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure herein is illustrated by way of example, and not by wayof limitation, in the figures of the accompanying drawings in which likereference numerals refer to similar elements, and in which:

FIG. 1A is a prior art representation of an optics assembly of a LIDARsensor including a boss protrusion;

FIG. 1B is a bottom view of a prior art representation of a LIDAR sensormount comprising mounting clips, fasteners, and a mating boss insert forthe boss protrusion of the prior art optics assembly of FIG. 1A;

FIG. 1C is a side lateral view of a prior art representation of anoptics assembly mounted to a LIDAR sensor mount with corresponding bossprotrusion and insert features and mounting fasteners;

FIG. 2A is bottom view of a LIDAR sensor mount comprising dovetailinserts for coupling to an optics assembly of a LIDAR sensor, accordingto examples described herein;

FIG. 2B is a side lateral view of a LIDAR sensor mount comprisingdovetail inserts for coupling to an optics assembly of a LIDAR sensor,according to examples described herein;

FIG. 3 illustrates an optics assembly of a LIDAR sensor comprisingdovetail joint inserts for coupling the optics assembly to correspondingdovetail septums of a LIDAR sensor mount, according to examplesdescribed herein;

FIG. 4 illustrates a LIDAR sensor assembly including an optics assemblycoupled to a LIDAR sensor frame using dovetail joint coupling features,according to various examples; and

FIG. 5 illustrates a combination of LIDAR sensor optical assembliescoupled to a multi-sensor mount via a set of dovetail joints, accordingto various examples described herein.

SUMMARY OF THE DISCLOSURE

LIDAR sensors are increasingly being used on vehicles such as airplanes,ships, boats, and automobiles for surveying or real-timethree-dimensional mapping of a surrounding environment of the vehicle. ALIDAR sensor instrument principally consists of a set of lasers and aset of corresponding photodetectors that detect return signals from thepulsed laser output of the set of lasers. Autonomous vehicles (AVs) inparticular employ an arrangement of sensors that collectively provide alive sensor view of the surrounding environment of the AV. AVs canemploy a set of LIDAR sensors that collectively generate a live,three-dimensional point cloud mapping of the AV's surroundingenvironment. In certain implementations, AVs can perform simultaneouslocalization and mapping using the live point cloud generate by the setof LIDAR sensors mounted to the AV. LIDAR data quality and granularitydepends on precision calibration of the lasers and photodetectors, aswell as the stability and secureness of LIDAR components.

FIG. 1A shows a prior art representation of an optics assembly 100 of aLIDAR sensor including a boss protrusion 102. FIG. 1B is a bottom viewof a prior art representation of a LIDAR sensor mount 105 comprisingmounting clips or brackets and fasteners 106, and a mating boss insert108 for the boss protrusion of the prior art optics assembly of FIG. 1A.FIG. 1C is a side lateral view of a prior art representation of anoptics assembly 100 mounted to a LIDAR sensor mount 105 withcorresponding boss protrusion and insert features 102 and mountingfasteners 106. Experienced disadvantages with such an arrangementinclude early wear in the mounting fasteners and clips 106 which can actas weak points for the overall system. Accordingly, failure or excessivewear of the mounting brackets or clips can result over time due to theforces of the spinning LIDAR sensor within the optics assembly 100, aswell as bouncing and jolting from the vehicle onto which the LIDARsensor mounted is attached.

To overcome the deficiencies of the prior art embodiments, examplesdescribed herein include an optics assembly of a LIDAR sensor. The LIDARsensor can comprise a set of lasers and a set of photodetectors disposedwithin the optics assembly. The optics assembly can include at least onelens and dovetail joint features that couple the optics assembly tocorresponding dovetail joint septums on a LIDAR sensor mount. Thedovetail joint can be configured to securely fasten the optics assemblyto the LIDAR sensor mount. In various aspects, the dovetail jointconfiguration for the optics assembly can eliminate the need for bossprotrusions, screws, screw holes, clips, brackets, and the like. Asdescribed, stresses due to the high-spinning LIDAR sensor within theoptics assembly and forces from normal vehicle operation can result infatigue in such components, which can result in costly failures,repairs, or misalignment. The dovetail joint configuration describedherein provides for a more robust fastening means, resulting inincreased stability and more secure and reliable alignment andorientation.

In certain implementations, the LIDAR sensor frame can comprise at leastone dovetailed septum to which the dovetail inserts of the opticsassembly of the LIDAR sensor may be joined. In certain aspects, themounting septum can further comprise a locking means (e.g., a spring andpin) that forces the optics assembly into a settled position whencoupled to the LIDAR sensor frame. In certain examples, the lockingmeans for securing the optics assembly to the LIDAR sensor frame can bea characteristic of the shape of the dovetail joint, in which thedovetailed mounting septum comprises a partial convex or irregularpolygonal or quadrilateral shape, such as that of a partial acute orisosceles trapezoid.

In certain implementations, the LIDAR sensor frame can include multipledovetailed septa upon which multiple LIDAR sensor optics assemblies canbe joined. In such examples, between each LIDAR sensor, the sensor mountcan comprise a dual dovetail septum that joins corresponding dovetailinserts of a pair of optics assemblies of LIDAR sensors, providing forthe ability to mount multiple LIDAR sensors using a single frame.

DETAILED DESCRIPTION

Reference is made herein to detailed embodiments, one or more examplesof which are illustrated in the drawings. Each example is provided byway of explanation of the embodiments, and not in limitation of thepresent disclosure. It will be apparent to those skilled in the art thatvarious modifications and variations can be made to the embodimentswithout departing from the scope of the present disclosure. Forinstance, features illustrated or described as part of one embodimentcan be used with another embodiment to yield a still further embodiment.Accordingly, it is intended that aspects of the present disclosure madefor illustrative purposes cover such modifications and variations.

Lidar Sensor Frame

FIG. 2A is bottom view of a LIDAR sensor frame 200 comprising dovetailjoint mounting septa 204 for coupling to an optics assembly of a LIDARsensor, according to examples described herein. The dovetail joint septa204 can be configured to replace conventional clips and fasteners (e.g.,screws, pins, and holes) utilized for mounting LIDAR sensors.Furthermore, the utilization of dovetail joint features described hereineliminates the need for a boss protrusion insert, such as the insert 108configured with the LIDAR chassis 105 shown in FIG. 1B.

FIG. 2B is a side lateral view of a LIDAR sensor frame 200 comprisingdovetail inserts 204 for coupling to an optics assembly of a LIDARsensor, according to examples described herein. The LIDAR sensor frame200 can comprise a chassis or supporting mount for a LIDAR sensor, andcan be mounted to a vehicle, such as an airplane or autonomous vehicle.As shown in FIG. 2B, a dovetail joint septum 204 can comprise a partialconvex or irregular polygonal or quadrilateral shape that, when matedwith a corresponding dovetail joint insert of an optics assembly of aLIDAR sensor, can securely fasten the LIDAR sensor to the sensor frame200. As further shown in FIG. 2B, the sensor frame 200 can includemultiple dovetail joint septums 204 (or septa) each of which can securea corresponding insert of the LIDAR sensor optics assembly.

In certain examples, the sensor frame 200 can further include one ormore locking means 206, such as spring-loaded locking pins, which can beautomatically or manually triggered to lock the dovetail joint insertsof the LIDAR sensor optics assembly to the sensor frame 200. Forexample, the locking means 206 can include a locking pin configured toengage a locking cavity of the optics assembly 300. In certain examples,a locking cavity can be formed into the dovetail joint insert 304 of theoptics assembly 300. In variations, the locking cavity can be formed ina base of the optics assembly 300. Once engaged, the locking means 206can prevent the LIDAR sensor from lateral or transverse movement causedby the vehicle's movement over uneven surfaces or during accelerationand deceleration, and/or the spinning LIDAR sensor within the opticsassembly. In some aspects, each of the locking means 206 can comprisecombination of locking features (e.g., a spring, screw lock, dowel pin,etc.). In certain variations, the locking means 206 can be configured atan angle to prevent movement along every axis of the LIDAR sensor.

In various aspects, between the dovetail septums 204, the sensor frame200 can include a mounting recess 213 into which the base of the opticsassembly of the LIDAR sensor can rest. The recess 213 can besubstantially the same width as the optics assembly of the LIDAR sensorto provide a secure fit for the LIDAR sensor. According to examplesdescribed herein, the base of the optics assembly of the LIDAR sensorcan slide or twist into place within the recess 213 until the dovetailinserts of the optics assembly as secured to the dovetail septums 204 ofthe sensor frame 200. In some examples, when the dovetail inserts of theoptics assembly are aligned with the dovetail septums 204, the lockingmeans 206 can be engaged, either automatically or manually by atechnician.

In certain implementations, the sensor frame 200 can be affixed to alarger sensor array mount of a vehicle, or to the vehicle itself. Forexample, the base 208 of the senor frame 200 can include brackets orfasteners that enable the sensor frame 200 to be bolted to the vehicle.In some aspects, the sensor frame 200 can be coupled to a vehicle by wayof welds or can be formed with the bodywork of the vehicle.

Lidar Optics Assembly

FIG. 3 illustrates an LIDAR optics assembly 300 of a LIDAR sensorcomprising dovetail joint inserts 304 for coupling the optics assembly300 to corresponding dovetail septums of a LIDAR sensor frame, accordingto examples described herein. In various implementations, the opticsassembly 300 can include a lens 302 through which laser light can beemitted and return signals can be detected by photodetectors of theLIDAR sensor disposed within. In certain examples, the lens 302 and theoptics assembly 300 can comprise a substantially cylindrical shape, orpartially conical shape, and the lens 302 can be formed to encompass theentire circumference of the optics assembly 300. The lens 302 can alsohave a height that is a fraction of the height of the optics assembly300, as shown in FIG. 3 .

With further reference to FIG. 3 , the optics assembly 300 can include aset of dovetail joint inserts 304 configured to couple with acorresponding set of dovetail joint septums 204 and/or locking means 206of a LIDAR sensor frame 200. In certain examples, the dovetail jointinserts 304 can comprise a protruding feature of the optics assembly 300having a shape that is substantially triangular, or an irregularpolygonal shape, and that corresponds as a mating feature of thedovetail joint septums 204 of the LIDAR sensor frame 200. It iscontemplated that the inserts 304 and the corresponding septums 204 ofthe sensor frame 200 can comprise any suitable shape and can be formedon a perimeter of the optics assembly 300. It is further contemplatedthat such dovetail joint inserts 304 can replace screw holes, fasteningbrackets or clips, and/or boss protrusions of conventional LIDARsensors.

In certain implementations, the dovetail joint inserts 304 can be formedwith the optics assembly 300 during manufacturing. For example, when ahousing portion of the optics assembly 300 (e.g., the optics assemblyminus the lens) is molded or otherwise manufactured, the dovetailinserts 304 can be formed to the optics assembly 300. In variations, thedovetail inserts 304 can be coupled to the optics assembly 300 as afashioned component post-manufacture. For example, the dovetail inserts304 can be manufactured separately from the optics assembly 300 and canbe mounted to the optics assembly 300 using a set of fastening means.

Lidar Sensor Assembly

FIG. 4 illustrates a LIDAR sensor assembly 315 including an opticsassembly 300 coupled to a LIDAR sensor frame 200 using dovetail jointcoupling features, according to various examples. Accordingly to variousexamples, the LIDAR sensor assembly 315 comprises an optics assembly 300with a LIDAR sensor disposed therein, and a LIDAR sensor frame 200, suchas the frame 200 described with respect to FIGS. 2A and 2B. Withreference to FIG. 4 , the optics assembly 300 is fastened to the LIDARsensor frame 200 via a dovetail joint. For example, the dovetail inserts304 of the optics assembly 300 are mated with the corresponding dovetailseptums 204 of the LIDAR sensor frame 200 such that the optics assembly300 is secured to the sensor frame 200.

In certain examples, the locking means 206 can be engaged with theoptics assembly 300 or the dovetail inserts 304 of the optics assembly300 once coupled. For example, the locking means 206 can comprise dowelsor pins fused or coupled to pre-loaded springs that, when aligned withcorresponding mating cavities of the optics assembly 300, engage to lockthe optics assembly 300 in place. In some examples, the optics assembly300 can be twisted into the sensor frame 200 until the dowels or pins ofthe locking means 206 align with the mating cavities of the dovetailinserts 304 of the optics assembly 300. As described, once the dowels orpins of the locking means 206 are aligned with the mating cavities ofthe dovetail inserts 304, the locking means 206 can engage the inserts206 to lock the optics assembly 300 in place.

In certain aspects, the dovetail inserts 304 and/or the dovetail septums204 can include one or more gaskets or protective lining to seal theoptics assembly 300 to the LIDAR sensor frame 200. In such aspects, thegasket(s) or lining can further provide cushioning for the LIDAR sensorand optics assembly 300 against harsh forces and jolts. In variations,the base of the optics assembly 300 or a coupling platform of the LIDARsensor frame 200 can include seals or gaskets to aid in affixing theoptics assembly 300 to the sensor frame 200.

In various examples, the base 208 of the LIDAR sensor frame 200 caninclude a set of mounting features 211, such as mounting brackets thatcan enable the sensor frame 200 to be coupled to a vehicle. For example,the mounting features 211 can enable the sensor frame 200 to be boltedor welded onto the bodywork or a larger sensor array frame on thevehicle (e.g., the roof of the vehicle).

FIG. 5 illustrates a LIDAR sensor assembly comprising a combination ofLIDAR sensor optical assemblies 400, 450 coupled to a multi-sensor mount500 via a set of dovetail joints, according to various examplesdescribed herein. In the example shown in FIG. 5 , the multi-sensormount or frame 500 dual dovetail septum 534 that joins correspondingdovetail inserts of a pair of optics assemblies 400, 450 of LIDARsensors, providing for the ability to mount multiple LIDAR sensors usinga single frame. In various aspects, the sensor mount 500 can include aproximal dovetail septum 504 and a distal dovetail septum 554, with thedual dovetail septum 534 therebetween. The combination can include afirst LIDAR sensor optics assembly 400 including a first set of dovetailinserts 404, and a second LIDAR sensor optics assembly 450 with a secondset of dovetail inserts 454. The first set of inserts 404 and second setof inserts 454 can be coupled to the corresponding dovetail septums 504,534, 554 of the multi-sensor mount 500.

Specifically, the proximal dovetail septum 504 can be joined with afirst dovetail insert 404 of the first optics assembly 400, with theother dovetail insert being joined to the dual dovetail septum 534. Thedual dovetail septum 534 can further be joined to a first dovetailinsert 454 of the second LIDAR sensor optics assembly 450. The distaldovetail septum 554 of the multi-sensor mount 500 can be joined to theother dovetail insert 454 of the second optics assembly 450.

A LIDAR sensor can be disposed within each of the optics assemblies 400,450. Further, each optics assembly 400, 450 can include a respectivelens through which pulsed laser light is outputted and return signalsare detected. In certain examples, each of the optics assemblies 400,450 can be locked and secured into place via a set of locking means, asdescribed herein.

Described throughout the present disclosure are example LIDAR sensormounts and optics assemblies featuring dovetail joints to secure LIDARsensors and provide robustness against the stresses of the operatingvehicle upon which the sensors are mounted, and the high-frequency,spinning LIDAR sensor within the optics assemblies. Embodimentsdescribed herein can act to secure LIDAR components as well as supportalignment of critical features of the LIDAR sensor, such as internallenses (e.g., a transmit lens throughout which laser pulses areoutputted and a receive lens through which target return signals aredetected). The dovetail joint embodiments described herein can furthersupport parallelism between the transmit and receive lenses of the LIDARsensors within the optics assemblies.

It is contemplated for examples described herein to extend to individualelements and concepts described herein, independently of other concepts,ideas or systems, as well as for examples to include combinations ofelements recited anywhere in this application. Although examples aredescribed in detail herein with reference to the accompanying drawings,it is to be understood that the concepts are not limited to thoseprecise examples. As such, many modifications and variations will beapparent to practitioners skilled in this art. Accordingly, it isintended that the scope of the concepts be defined by the followingclaims and their equivalents. Furthermore, it is contemplated that aparticular feature described either individually or as part of anexample can be combined with other individually described features, orparts of other examples, even if the other features and examples make nomention of the particular feature. Thus, the absence of describingcombinations should not preclude claiming rights to such combinations.

1-20. (canceled)
 21. A LIDAR sensor system comprising: a multi-sensorframe comprising a plurality of joint septums and a dual joint septum;and a plurality of assemblies, a first assembly of the plurality ofassemblies comprising a LIDAR sensor and a first plurality of jointinserts, and a second assembly of the plurality of assemblies comprisinga sensor and a second plurality of joint inserts; wherein the pluralityof joint septums and the dual joint septum are coupled to the firstplurality of joint inserts and the second plurality of joust inserts,wherein the plurality of joint septums and the dual joint septumcomprise a proximal joint septum and a distal joint septum with the dualjoint septum therebetween, wherein the first assembly is mounted betweenthe proximal joint septum and a first side of the dual joint septum, andwherein the second assembly is mounted between a second side of the dualjoint septum and the distal joint septum.
 22. The LIDAR sensor system ofclaim 21, wherein the second assembly is configured to twist or slide ina recess of the multi-sensor frame to align the first plurality of jointinserts of the first assembly with the proximal joint septum and thefirst side of the dual joint septum.
 23. The LIDAR sensor system ofclaim 21, wherein the multi-sensor frame further comprises a pluralityof mounting features to enable the multi-sensor frame to be mounted to avehicle.
 24. The LIDAR sensor system of claim 23, wherein the vehicle isan autonomous vehicle.
 25. The LIDAR sensor system of claim 21, whereinthe LIDAR sensor of the first assembly is a spinning LIDAR sensor. 26.The LIDAR sensor system of claim 21, wherein the sensor of the secondassembly is a LIDAR sensor.
 27. The LIDAR sensor system of claim 21,wherein: the multi-sensor frame further comprises a first plurality oflocking means securely fastening the first assembly to the multi-sensorframe; and the first plurality of joint inserts are aligned with theproximal joint septum and the first side of the dual joint septum. 28.The LIDAR sensor system of claim 21, wherein: the multi-sensor framefurther comprises a second plurality of locking means securely fasteningthe second assembly to the multi-sensor frame; and the second pluralityof joint inserts are aligned with the distal joint septum and the secondside of the dual joint septum.
 29. The LIDAR sensor system of claim 21,wherein the plurality of joint septums are dovetail joint septums. 30.The LIDAR sensor system of claim 29, wherein the dual joint septum is adual dovetail joint septum.
 31. An AV control system comprising: aplurality of joint septums and a dual joint septum coupled to a firstplurality of joint inserts of a first assembly of a LIDAR sensor tosecure the first assembly and a mounting recess between a proximal jointseptum of the plurality of joint septums and a first side of the dualjoint septum and a second plurality of joint inserts for a secondassembly.
 32. The AV control system of claim 31, wherein the firstassembly is configured to twist or slide in the mounting recess of theLIDAR sensor frame to align the first plurality of joint inserts of thefirst assembly with the proximal joint septum and the first side of thedual joint septum of the LIDAR sensor frame.
 33. The AV control systemof claim 31, further comprising: a plurality of mounting features toenable the LIDAR sensor frame to be mounted to a vehicle.
 34. The AVcontrol system of claim 33, wherein the vehicle is an autonomousvehicle.
 35. The AV control system of claim 31, further comprising: aplurality of locking means securely fastening the LIDAR sensor frame tothe first assembly, wherein the first plurality of joint inserts and theproximal joint septum and the first side of the dual joint septum arealigned.
 36. The AV control system of claim 35, wherein at least onelocking means of the plurality of locking means comprises a locking pinthat engages a locking cavity of the first assembly.
 37. The AV controlsystem of claim 36, wherein the locking cavity of the first assembly ispositioned within a joint insert of the first plurality of jointinserts.
 38. The AV control system of claim 35, wherein: the pluralityof locking means automatically engage with the first assembly; andwherein the first plurality of joint inserts and the proximal jointseptum and the first side of the dual joint septum are aligned.
 39. Anautonomous vehicle, comprising: a multi-sensor frame comprising aplurality of joint septums and a dual joint septum; a plurality ofassemblies, a first assembly of the plurality of assemblies comprising aLIDAR sensor and a first plurality of joint inserts, and a secondassembly of the plurality of assemblies comprising a sensor and a secondplurality of joint inserts; and a plurality of mounting features toenable the multi-sensor frame to be mounted to the autonomous vehicle;wherein the plurality of joint septums and the dual joint septum arecoupled to the first plurality of joint inserts and the second pluralityof joint inserts, wherein the plurality of joint septums and the dualjoint septum comprise a proximal joint septum and a distal joint septumwith the dual joint septum therebetween, wherein the first assembly ismounted between the proximal joint septum and a first side of the dualjoint septum, and wherein the second assembly is mounted between asecond side of the dual joint septum and the distal joint septum. 40.The autonomous vehicle of claim 39, wherein the second assembly isconfigured to twist or slide in a recess of the multi-sensor frame toalign the first plurality of joint inserts of the first assembly withthe proximal joint septum and the first side of the dual joint septum.